Automotive electrical connectors are critical for safe and efficient operation of a vehicle. However, their durability is limited by fretting-corrosion. This type of surface damage is observed between two mated surfaces subjected to vibrations and thermal cycling. Such conditions occur during normal vehicle operation causing two parts of an electrical contact to move in relation to each other with high frequency and small displacement amplitude -Typically tens or hundreds of microns. This generates damage of both surfaces, wear particles arc produced and subsequently oxidised in air atmosphere. As a result, an oxide film is formed at the interface, which isolates both surfaces and increases electrical resistivity leading to the contact failure. It is shown in this study, how electrical contact durability can be extended by a surface design approach, which controls the metallic interface and assures low contact resistance. The approach links imposed surface geometry to the progressive process of interface oxidation. A relationship between surface roughness and electrical contact durability has been observed.
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